Involute flanks are nominally well described and classified by different standard accuracy grades@ depending on gear application and defining their tolerance limits for such parameters as runout@ profile@ lead@ pitch variation@ and others. The gear tooth fillet is an area of maximum bending stress concentration. However@ its profile is typically marginally described as a cutting tool tip trajectory. Its accuracy is defined by a usually generous root diameter tolerance. The most common way to reduce bending stress concentration is application of the basic (or generating) rack with full radius. This paper presents a fillet profile optimization technique based on the FEA and random search method@ which allows for a substantial bending stress reduction@ by 15 to 30% compared to traditionally designed gears. This reduction results in higher load capacity@ longer lifetime@ and lower cost. It includes numerical examples confirming the benefits of fillet optimization.